N_ARC CONSULTING

TECHNICAL
SPECIFICATION FOR
11KV DG SET
Rail Coach Factory, Rae Bareli.
IRCON International Limited
18/02/2011

(This document is property of IRCON & is meant for the exclusive purpose of bidding against this
specification and shall not be transferred, reproduced or otherwise used for purposes other than that
for which it is specifically issued.)
N_Arc Consulting IRCON

DIESEL GENERATOR SET

1. GENERAL

1.1 Scope

The specification covers the design, manufacture, supply & delivery, transportation &
erection, testing at site & commissioning of 1000 KVA 11 kV Diesel Generator sets with
diesel engine suitable for HSD fuel and the generator having net output of 1000 KVA
each at 0.8 p.f. after meeting auxiliary loads, including fuel tanks, complete with,
ventilation system, exhaust system power panel, control & monitoring panels etc. As
detailed in the schedule of requirement of this specification.

1.2 Summary

Equipment and services to be provided shall include but are not limited to:

a) Supply of 1000 KVA Diesel engines having min. 1180 BHP with shaft mounted
radiators Coupled with 11KV Alternator.

b) Engine instrument panel-Microprocessor Based required as described in Data sheet

c) Starters, batteries and battery chargers suitable for 24V DC

d) Electronic governors having Class A1 Governing

e) Engine lubrication systems including pumps, piping, oil coolers, and oil Filters and
reservoir

f) Exhaust silencers (residential type) with Flexible Exhaust (SS) bellow as required to
complete Exhaust system.

g) Structural steel for mounting supports of exhaust and other accessories

h) Mounting of control and switching equipment to the concrete Foundation, separate

from the Generator frame.

i) Foundation Bolts

j) Safety shutdown controls

k) 990 litre Fuel day tanks complete with high & low level indicator and side glass
gauge for Measurement of fuel oil in the day oil tank & accessories as required.

l) Supply if Neutral Isolation panel cum NGR panel for DG set. (The Neutral Grounding
Resistor shall be designed to limit the Volt current to full load value. The Neutral
Grounding Resistor will be housed in a cubicle and will be of Stainless Steel or Cu/Ni
Alloy. The rating of Neutral Grounding Resistor will be for 10 second with
temperature rise limitation of 375° above ambient.)

Pa ge |2
N_Arc Consulting IRCON

m) Power panel consist of VCB.

n) Obtaining statutory approval shall be done by purchaser.

o) Room Treatment of DG set if required shall be done by purchaser

p) Ventilation system of DG room suitable for 6 DG set by purchaser

q) Cables and wires complete with terminal lugs accessories for control metering
relaying alarms, Carrier and communication AC, DC station power and lightning and
any other cables and wire Required to interconnect all equipment of the entire
system by purchaser.

r) Ventilation & illumination provision in Generator room by purchaser

s) All civil work including foundation, cable duct and Power House by purchaser

t) Dismantling /removing of existing structure/ equipment wherever required by purchaser.

u) The Contractor shall undertake a detailed analysis and observation of existing 11 KV

cubicles where they need to interlock the supplied panel. All the installation &
interlocking work has to perform by bidder. The detailed plan of DG room will furnish to
bidder after finalize the contract by purchaser.

1.3 Codes and Standards

The design, material, construction, manufacture, inspection, testing and performance of

the engine/generator sets shall comply with all currently applicable standards, regulations
and safety codes in the locality where the equipment shall be installed. The equipment
shall also conform to the latest applicable standards and codes of practice.

1.4 Delivery and Handling

The engine/generator sets shall be delivered to site properly packaged and mounted on
pallets or skids to facilitate handling of heavy items. Factory- fabricated type containers or
wrappings shall be utilized for engine/generator and components, which shall protect
equipment from damage.

Engine-driven generator equipment shall be handled carefully to prevent physical damage

to equipment and components.

1.5 Warranty

Manufacturer's guarantees and warranties shall be in accordance with General terms and
conditions. The warranty period shall be for a 18 months from the date of dispatch or 12
months from the date of commissioning or minimum 5000 Hours whichever is earlier.

Pa ge |3
N_Arc Consulting IRCON

1.6 Site Water/Power:

For construction and installation of DG set at site water and power shall be provided at
one single point(max. 30 mtr) free of cost, however further distribution to the DG site shall
be in vendor scope of work.

1.7 Variation in Quantity:

The Quantity listed in price schedule represents the estimated quantities for tender
purpose only. The contractor agrees to make no claim for the anticipated profit or for
alleged losses because of any difference quantities actually furnished and installed and
the estimated quantities as indicated in the Tender document

1.8 Spares:

The contractor shall be provided consumable spare parts for one year (or 1500 Hours). The
list of Consumables spare parts should be clearly mentioned in the offer with the part no.

2.0 Supervision personnel:

The contractor should furnish the qualified supervision personnel for the installation,
testing & commissioning and final system testing and checking out of the equipment list in
close corporation and collaboration with the team of employer.

3.0 Time Schedule and Progress Report.

3.1 Within 30 days from the date of signing of the contract, the contractor shall submit the
progress chart covering work to be done at each manufacturing plant. The Contractor
shall show the several salient features of work.

3.2 The Bidder shall submit the project schedule prepared by PERT /CPM after the award of
contract.

3.3 The time schedule will be subject to review by the Employer for compliance with the
Contract documents and shall be revised if necessary by the Contractor to bring it into
such compliance

3.4 The Contractor shall prepare and submit monthly report to the Employer covering the
progress on Manufacturing and installation work at the site during the month of record.
The reports shall be accompanied by suitable illustration and photographs and by copies
or working schedule as necessary to effectively evaluated and document the progress of
the work. The report shall cover at least the following activities:

a) Manufacturing status of equipment

b) Shipping status.
c) Arrival of equipment and schedule for arrival of other required equipment.
d) Installation of Contractor’s equipment at the site.
e) Quantitative progress on work at the site.
f) Schedule progress on work at the site.

Pa ge |4
N_Arc Consulting IRCON

g) Description of conditions encountered that have affected the progress of the

works adversely and of action taken alleviates the conditions and regains the
anticipated progress.
h) Number of employee in various categories at the site.
j) Schedule showing the progress of planned of planned and actual for each salient
activities of the work.

3.5 Contractor’s Drawing and Data

3.5.1 Prior to commencement of the work, the contractor shall submit detailed design drawings
and data to the Employer for approval. Employer direct that modifications be made in
order to satisfy the requirement of the specifications, the Contractor shall submit revised
drawings for approval. Alteration in the Contract price shall not be allowed by reason of
the drawing modifications.

3.5.2 The Metric system shall be used and notation shall be made in English, Drawings,
calculation and data shall be furnished as specified. All drawings data will be subject to
review by the Employer conformity with Technical specifications and Contract Drawings.

3.5.3 The Contractor shall prepare and furnish to the Employer such Drawing calculation and
data on material and equipment.

3.5.4 All the instruction, manual and relevant information in the drawing must be in English.
Unless otherwise specifically mentioned, the drawings and data pertaining to the works
shall be according to this clause.

3.5.4.1 Shop Drawings

Shop drawings including overall engine/generator set dimensions, equipment mounting,

locations, and interconnect points from load levels, fuel, exhaust, and cooling systems
shall be submitted for Consultant’s approval. Spatial relationship of Engine/generator sets
to associated equipment shall be shown. Connections, mounting, and support provisions
and access and workspace requirements shall be shown. Adequate clearance space for
removal of engine/generator set elements for maintenance purposes shall be allowed.

General arrangement drawings showing locations of auxiliary components in relation to

engine/generator sets and piping, and wiring connections between generator sets and the
auxiliary equipment shall be included.

3.5.4.2 Wiring Diagrams

Copies of wiring diagrams for engine/generator sets showing power and control
connections at the generator control panel, and the wiring connections between the
generator sets and the auxiliary equipment shall be provided.

3.5.4.3 Generator Manuals

Complete bound instruction manuals, including parts list for the generators and all
equipment devices furnished with the generator shall be provided. The manuals shall give
complete and detailed instructions for installation, maintenance, operation under both
normal and abnormal conditions, and adjustments.

Pa ge |5
N_Arc Consulting IRCON

4 DIESEL ENGINE

4.1 Section – 1

4.1.1 Regulations and Codes & Standards:

All pants and Auxiliary equipment supplied under this contract shall conform to or
be of higher quality than the latest applicable standard as listed in the following:

IEC - International Electromechanical Commission

ANSI - America National Standard Institute
BS – British Standard
NEMA - National Electrical Manufacturers Association
IEEE - Institute of Electrical and Electronics engineers
ASME - American Society of Mechanical Engineer
ISO - International Organization for standard

i) Diesel Generators

a. Equipment:

Diesel Engine
BS- 5514, ISO 8528, and as per standard practice of Diesel engine
manufacturer’s association of USA.

Generator
IS-4722/ IEC-60034, IS12065, IS12075
Diesel Fuels – Specifications IS1460

b. Installation:

The installation work shall conform to Local Electricity Rule as amended up to the
date this specification is issued. Any approval required from statutory authorities
shall be obtained by the Client however all the necessary drawing and document
for approval shall be provided by contractor.

c. Type

Diesel Engine

Stationary type, four strokes with Vertical in line or ‘V’ type cylinder arrangement
and turbo charged, air cooled.

ii) RATING & GENERAL DATA

The ratings & electrical characteristics of the Diesel engine & associated generator Shall be
as under

Pa ge |6
N_Arc Consulting IRCON

iii) NORMAL INFORMATION

A) Diesel Engine

1) Particulars of specification : ISO-3046 and BS: 5514

2) Type : Direct injection, four stroke cycle, cold starting

3) Number of cylinder : 12 cylinders and ‘V’ shape orientation of cylinder

4) Rated continuous output (Prime) : Suitable for net generator after deducting all auxiliary
output of 1000 KVA at 0.8 p.f. power consumption and
also underrating for Site elevation & temperature.
5) Speed : 1500 rpm.
6) Over load in percentage at : 10% rated speed for one hour in any period of 12 hours
consecutive running.
7) Starting time : 10-15 sec.
8) Cooling system : Water-cooled, radiator

9) Air intake system : Turbo charger with after cooler. Turbo charger with
minimum speed at no load/full load is preferred)
10) Starting System : By battery starting

11) Governing system : Class A-1 as per BS 5514 Governing system

12) Fuel Injection system : Direct injection system

13) Exhaust height : As per statutory requirement
15) Design temperature : 50 deg C

Pa ge |7
 N_Arc Consulting IRCON

5.0 Technical Requirements required for Diesel Engine shall have following:

Cummins Engine / Caterpillar Engine / L& T Engine/ Perkins Engine developing min.1180 BHP at
1500 RPM at 50 degree temperature under NTP conditions, water cooled, four stroke, 12 cylinder,
electric start, turbocharged & after cooled model, conforming to BS : 5514 with capacity of 10% over
loading for one hour in twelve hours duration having the following technical specs :-
AIR INTAKE SYSTEM
i) Air intake manifold.
ii) Dry type air cleaner.
iii) Vacuum indicator.

EXHAUST SYSTEM
i) Holset Turbocharger.
ii) S.S Flexible connection.
iii) Pulse Tuned Exhaust manifold.
iv) Residential silencer

COOLANT SYSTEM
v) Engine water pump.
vi) Radiator
vii) Coolant additive concentrate
viii) By pass thermostat.

LUBRICATING SYSTEM
i) Oil pan.
ii) Engine mounted lube oil pump
iii) Full flow lube oil filter.
iv) Lube oil by-pass filter.

FUEL SYSTEM
i) PT fuel pump.
ii) Heavy duty STC injector.
iii) 24V DC solenoid coil.
iv) Replaceable fuel filter.

STARTING SYSTEM
i) 24V DC electric starter.
ii) 24V DC battery charging alternator.

OTHERS
i) Vibration damper.
ii) Flywheel with housing.

Pa ge |8
N_Arc Consulting IRCON

6. 0 DIESEL ENGINE

6.1 Construction

6.1.1 The Diesel Engine shall be 4 cycle, multi cylinder, heavy-duty industrial type with rated
electrical output. Engine shall be rated generally in accordance with the Equipment
Schedule.

6.1.2 Cylinder housing and crank case shall be of high grade cast iron with overhead valves.
Housing and heads shall be provided with necessary cooling fins.

6.1.3 Crank shaft shall be manufactured from solid forging with hardened crank pin and main
bearing journals. The entire shaft shall be truly balanced.

6.1.4 Pistons shall be of close grained cast iron of aluminum alloy and provided with
necessary compression and scrapper rings and a fully floating gudgeon pin.

6.1.5 Connecting rods shall be H-section steel stampings. Camshaft shall be gear driven (fly-
wheel end) and easily removable. Fly wheel shall be accurately balanced meeting the
requirements of cycle variation as set down in BS: 649.

6.1.6 Lubrication system shall be complete with necessary gear pump, piping and drilled oil
passage strainer, oil cooler etc. and relief valve.

6.2.2 Fuel System

6.2.2.1 Fuel injection equipment shall be low pressure PT self adjusting direct injection fuel
system built in fast response electronic fuel control governor for isochronous and droop
governing characteristics. Premium Step timing Control (STC) injector with ceramic
components have more durability and provide high injection pressure for better fuel
economy. STC improve startabilty part load fuel efficiency and minimize white smoke at
idle condition during cold start up.

6.2.2.2 A tank of specified capacity shall be provided for lasting at least for 10 hour period or 990
ltrs. The tank should be complete with filter breather unit and drain plug.

6.3 Filtration

6.3.1 The engine shall have cleanable fuel oil filters. Lub oil filtration shall be through strainers
which are capable of being cleaned when the engine is running. Air filtration shall be
through cleanable dry type filters.

6.4 Cooling System

A two pump Two loop system i.e separate cooling circuit for engine jacket and after
cooler independent of each other, gear driven centrifugal water pump, four modulating by
Pass thermostat to regulate coolant temperature, corrosion inhibitor to check rust and
corrosion control acidity and remove impurities.

Pa ge |9
N_Arc Consulting IRCON

6.5 Engine Exhaust

6.5.1 The engine exhaust piping shall be amply sized for minimum back pressure and
connected to the engine manifold through flexible connection on one side and to a
silencer on the other side. The silencer shall be packed type with adequate attenuation
for urban use (Residential type), constructed from heavy gauge galvanized steel. The
sound absorbent infil shall be no hygroscopic, vermin proof, non-combustible material.
The silencer should be adequately sized to impose minimal additional aerodynamic
loading on rotor fans.

6.5.2 The exhaust piping from the silencer on wards shall be led up to the top most level and
discharged through a rain cowl as shown on drawings. Entire exhaust piping and
silencer shall be insulated with 75mm thick and 48Kg/cum density fiberglass white wool.
The insulation shall be held in position with galvanized steel wire mesh 0.63 dia 20 mesh
and finished neatly with 26 SWG Aluminum cladding.

6.5.3 The exhaust piping shall be fabricated with ERW pipe as shown in the equipment
schedule and all flanged joints. The piping shall be installed with necessary thermal
expansion facility as required and shown on drawings.

6.6 Safety and Control Systems

6.6.1 The Governor should be an independent essential ancillary employing electric /

electronic control through preferably a microprocessor based control system. The system
should be isochronous with 3% droop and suitable for auto start and auto synchronizing.
A governor shall trip the engine at the pre-set over-speed and shut-off the fuel supply.

6.6.2 The engine cooling water temperature shall be monitored by a two point thermostat
which should actuate an audible cum visible alarm at one point and trip the engine at the
second point. Likewise the low oil pressure cut-out shall trip the engine with visible
indication.
Other safety controls and indicating instruments shall be as shown in Equipment
Schedule ES 01.

6.7 Engine Starting

6.7.1 The engine shall be electrically started and the battery shall be 24V lead acid automotive
type and rated for 4 (four) consecutive starting kicks and the continuous drain for signals
and controls. All batteries shall be complete with associated charger incorporated in the
generator panel. The starting system shall be complete with necessary relays &
solenoid valves for fuel, control and indicating panels as specified and required.

6.8 Mounting and installation

6.8.1 A common rigid bed plate shall be provided for the engine and alternator which shall be
flexibly coupled. The coupling must be done after ensuring proper alignment of
generator and engine shafts.

P a g e | 10
N_Arc Consulting IRCON

6.9 Engine Governors

The engine/generator sets shall be provided with electronic governors suitable for
unattended automatic paralleling and load sharing with the DG set. The steady state
frequency regulation shall be + 0.25 percent. They shall be capable of sharing load within 5
percent when paralleled with similarly equipped engines. Speed shall be sensed by a
magnetic pickup off the engine flywheel ring gear. A provision for remote speed adjustment
shall be included. Engine governor shall be as per ISO 3046 Class A1.

The fuel injection system shall be electronically controlled & shall vary depend on the
engine loads to economize the fuel consumption in case of lesser loads.

7. ALTERNATOR

7.1 General parameters

ALTERNATOR:

Synchronous alternator of Synchronous alternator of Leroy-Somer / Stamford / Kirloskar

make of 1000 KVA rating, double bearing, suitable for continuous operation at 1500 RPM
generating 11 KV at 45°C temperature, 0.8 p.f. (lag) 50 Hz, 3 phase system. The
alternator shall be Brushless type, separately excited (PMG) & self regulated through an
AVR. The alternator will be suitable for tropical climate and shall generally confirm to IS:
4722. The salient features of the alternator are: -

a) The alternator shall be Double bearing type suitable for coupling to the
engine. It shall be drip proof screen protected in accordance with IP23.

b) The alternator shall be continuously rated and shall have class ‘F’
insulation designed and built to withstand tropical conditions. It shall be
conforming to B.S: 5000(Part-99) or IS: 4722.The output of the alternator
shall be suitable rated output at site conditions at 0.8 lagging power
factor.

c) Six nos. embedded resistance temperature detector (RTDs) of platinum,

100 ohms resistance at 0 degree to measure the winding temperature
and 2 Nos. BTDS to measure bearing temperature shall be provided.

d) The leads of embedded RTDs shall be wired up to the terminal block in a

separate terminal box.

e) All external nuts and bolts shall be of high tensile steel only.

f) Alternator shall be provided with anti-condensation space heater of

adequate rating suitable for 240V/110V, 50 Hz, 1 phase AC supply and
shall be wired up to a separate terminal box.

P a g e | 11
N_Arc Consulting IRCON

g) The independent earth terminals on the frame, complete with nuts, spring
washer shall be provided.

h) Alternator shall be with suitable flanges for termination of Aluminum

conductor/cables. Suitable arrangement shall be provided in the terminal
box for Earthing.

i) Alternator shall be brushless, synchronous, revolving field, air cooled and

drip-proof.

j) The alternator shall be capable of withstanding, without adverse effects,

over-speeds of 25 percent above the synchronous speed for the duration
of one minute.

7.1.2 Excitation system

The alternator shall be provided with a complete rotating diode type brushless excitation
system, capable of supplying the excitation current of the generator under all conditions of
output from no load to full load and capable of maintaining voltage of the generator
constant at one particular value.

The exciter shall have class “F” insulation.

The excitation system shall comprise a shaft driven AC exciter with rotating rectifiers. The
rectifiers shall have built-in protection for over voltage.

The exciter shall be fast response type and shall be designed to have a low time constant
to minimize voltage transients under severe load changes.

No external supply shall be required during starting and normal running of the alternator.
A) Generator
1) Output of Generator : 1000 KVA at 45 Deg C
2) Rated guaranteed continuous : Not less than 1000 KVA
3) Rated voltage : 11 kV
4) No. of phases. : 3 (phase) 3 wire systems
5) Frequency : 50 Hz

6) Insulation class for stator : Class F with temperature rise limit to Class F
& Rotor winding.
7) Over loading above rated : 10% for one hour in every 12 hours of operations and
50% overload
For 30 sec

P a g e | 12
N_Arc Consulting IRCON

8) Voltage regulation : The voltage under steady state condition within +0.5% of
the rated voltage for all loads between no load to full
load at 0.8 p.f.
9) Noise level : As per statutory requirement

10) Vibration. :< 2.5 Micro mm

11) Excitation : Static brushless.
12) Short circuit ratio : As per manufacture standard

13) Enclosure : IP 23

14) Power Factor : 0.8 (Lag)

8. Battery Charger

Trickle type battery charge of suitable capacity intended to operate on single phase 230
volts, so cycles supply system and suitable for charging current. The battery charger will
be provided with the following accessories.

 AC and DC “ON” and “OFF” switches with HRC fuses

 Indicating lamps for indicating mains “ON” and battery charging

8.1 Batteries required for Engine starting only:

Batteries of Exide / Amaron (Quanta) / HBL / Okaya / Cummins pulse lite make
maintenance free of 12V- 160 AH (2 Nos )

Technical specification of 12 volt batteries shall be as described in below data sheet

along with connecting leads mounted on suitable frame work. Battery shall have

sufficient capacity to provide for the engine/generator safety circuits,

P a g e | 13
N_Arc Consulting IRCON

General Information Specification

Sealed Maintenance free, Pure Lead-Tin, Valve regulated Lead acid
Battery Type Monobloc Battery. Type PLT 160-12A
Part No AX1012845
Nominal Voltage 12V
Description High Power, sealed lead acid, engine starting battery
Nominal Capacity at 20 hr rate to end
10.5V/b (1.75V/cell) at 25 deg C 160 Ah
Normal Operating Temperature 20 deg C to 30 deg C
Operating Temp range (-) 40 dec to + 55 Deg C
Physical Characteristics
Plate design High purity lead-tin alloy. Prismatic cell configuration.
Case ABS
Colour Light Gray
Length 525
Width 220
Height 250
Minimum Weight (Kg) 56
Type Post/Terminal Conical differential terminals confirming to SAE standards
Material : Brass for better conductivity
No. of plates 31
Performance
Open Circuit Voltage (Fully Charged) More than 12.80 V
Internal Resistance (Fully Charged-ohms) 2.5 mW
Capacity (C/20 rate) 160
CCA @ 0F 1500
Cranking Amps @ 32F 1700
Cranking Amps @ 80F 2100
Usable reserve Not Applicable
Shelf life @ 25C 3 months
Cycle life Not Applicable
Life (Cradle to grave) 3 Years
Transport class Sealed battery. No free electrolyte
Environmental designation After completion of useful life of the battery, it has to be re-cycled
at authorised re-cyclers as per the Battery (Management and
Handling) Rules, 2000, Ministry of Environment and Forests.

9.0 BASE FRAME:

Suitable base frame of sturdy design made of M.S. channel with necessary reinforcement
and pre-drilled holes.

10.0 DG SET CONTROLLER -( Power Command Control)

The Power Command Control is a microprocessor-based generator set monitoring,
metering, and control system. The control provides an operator interface to the Genset; digital
voltage regulation, digital governing, and generator set protective functions. The integration of all
the functions into a single control system provides enhanced reliability and performance compared
to conventional control systems.

P a g e | 14
N_Arc Consulting IRCON

S No Description Required Remark

P a g e | 15
N_Arc Consulting IRCON

1 AMF compatible Yes

2 Start Delay Yes
3 Programmable cyclic crank Yes
4 Starter Protection Yes
5 In Built Governor Yes
6 In Built Digital AVR Yes
7 Smart starting Logic Yes
8 Battery Monitoring Yes
9 Engine Monitoring
Starting Battery Voltage Yes
Engine Coolant Temperature Yes
Lube Oil Pressure Yes
10 Alternator Monitoring
Current Yes
Voltage Yes
Frequency Yes
KW Yes
KWH Yes
KVA Yes
Pf Yes
11 Engine Protection
Over Speed Shutdown Yes
Low Lube Oil Pressure Warning /Shutdown Yes
High Coolant Temperature Warning / Shutdown Yes
Low Coolant Level Warning / Shutdown Yes
Low Coolant Temperature Warning Yes
Low & High Battery Voltage Warning Yes
Weak Battery Warning Yes
Dead Battery Shutdown Yes
Over Crank ( Fail to Start) Shutdown Yes
Fail To Crank Shutdown Yes
12 Alternator Protection
Over Current Warning/ shutdown Yes
Short Circuit Shutdown Yes
High / Low Voltage shutdown Yes
Under / Over Frequency shutdown/ warning Yes
Reverse Power (KVA & KVAr) shutdown Yes
Excitation fault(Loss of Voltage sensing Input to control) Yes
shutdown
13 Amp Sentry Protection Yes
14 Speed Bias Yes
15 Voltage Bias Yes
16 Remote Monitoring Yes
17 BMS Compatible Yes

P a g e | 16
N_Arc Consulting IRCON

11.0. Testing, Commissioning and Trial Runs: at site

Contractor shall carry out the following works within the indicated rates.

a. Importing (if required), loading, unloading, handling, transporting to site, installing,

testing and commissioning DG set.

b. Trial run of the set for a minimum period of 2 hours continuously on 50% Load. On
satisfactory completion of 50% load run the set shall be run for a 6 hours at 100%
load. All consumables i.e. fuel oil etc shall be made available by and the cost of same
borne by the Client for testing.

c. Handing over of the entire work after satisfactory completion, testing and
commissioning along with 3 sets of documents consisting of detailed data and
catalogue of the equipment.

Before dispatch of the equipment it shall be got inspected (if so required by Owners) by
the Architect / Engineer-in-charge / Consultants .

12.0 Equipment Data

The following information’s regarding the equipments offered shall be furnished by tenderer along
with tender. The tendered should fill out this Proforma and attach to his offer along with technical
catalogues / details without which the offer may not be considered.

DATA SHEET A

EMERGENCY DIESEL GENERATOR - 1000 KVA

  DATA SHEET- B ( To be filled up by Bidder )    

   
  Bidder's Name    
Sl.
DIESEL ENGINE- GENERAL DATA Unit  
No.
1 Designation   Diesel Generator
2 No. of Diesel Generators Offered    
3 Tag Numbers    
4 Manufacturer’s Name,    
4.1 Make
4.2 Model No.
4.3 BHP (min.) BHP
4.4 RPM RPM
4.5 Over Speed setting RPM
5 Standard Rating at ISO Conditions  

P a g e | 17
N_Arc Consulting IRCON

5.1 At NTP Condition KW

5.2 At Site Condition KW
6 Derating factors due to :    
6.1 Harmonics %  
6.2 Altitude @ 1250 Meter %  
6.3 Inlet air Temperature %  
6.4 Humidity %  
6.5 Ambient @ 50 Deg C %
Prime rating of the DG set based on continuous operation for

365 days in a year at varying loads.

7 KW  
The prime rating as above shall be suitable for continuous operation over
an ambient of 50OC. Tendered to categorically confirm this operation and
to furnish design calculation in support of this confirmation.
Maximum Engine Rating at Site conditions with 10%
8 KW  
overload
9 Number of cylinders    
10 Arrangement of cylinders    
11 Direction of Rotation as viewed from free end    
12 Operating speed RPM  
13 Number of strokes    
13.1 BoreX Stroke mm
13.2 Compression Ration
13.3 BMEP Kpa
14 Piston Speed M/sec  
15 Governor
15.1 Class A1 Digital Governing
16 Minimum acceptable Lube Oil Temperature at start-up °C  
Maximum period for which the engine can operate without
17 Min  
cooling water supply
Foundation bolts and anti vibration pads questionnaire to be
18 Yes/No  
provided
  FUEL OIL SYSTEM    
1 Day Tank    
2 Number of day tanks    
3 Capacity-Each Litres  
4 Material of construction    
5 Thickness of shell    
6 Hand operated fuel oil pump provided Yes/No  
  LUBE OIL SYSTEM    
1 Filters    
2 Type    
3 Number    
4 Grade of lube oil to be used    
       
 
  AIR INTAKE & EXHAUST  
1 Intake filter type dry / wet  

P a g e | 18
N_Arc Consulting IRCON

Residential /
2 Exhaust Silencer type  
Industrial
       
  STACK    
1 Flow rate of flue gases leaving DG M3/Hr  
0
2 Temperature of flue gas leaving DG set / Entering stack C  
3 Stack diameter x height M  
4 Number of flue gas openings    
5 Flue gas connection size(Exhaust dia) M  
Height of flue gas connection centre-line above foundation
6 M  
level
       
  ALTERNATOR & ACCESSORIES    
1 Manufacturer’s name    
2 Design rating KW  
3 Maximum rating at site KW  
4 Power Factor    
5 Rated Voltage KV  
6 Rated Current / Phase Amps  
7 Speed RPM  
8 Frequency Hz  
9 Field current at rated output and voltage Amps  
10 Insulation Class F with Temperature rise limit to Class B    
12 Efficiency    
12.1 50% load %  
12.2 75% load %  
13.3 100% load /full load %  
14 KW rating of space heaters KW  
15 Transient Reactance’s    
15.1 X’d %  
15.2 X’d %  
16 Degree of protection  IP:23  
       
  EXCITATION SYSTEM    
1 Brushless  
       
  AVR    
1 Type-Digital    
       
Fuel oil consumption Lts / Hr  
1 at 50% load    
2 at 75% load    
3 at 100% load    
4 Lube oil consumption Litre/Hr  
       
  WEIGHT SCHEDULE    

P a g e | 19
N_Arc Consulting IRCON

1 Weight of engine Kgs  

2 Total shipping weight Kgs  
3 Weight of generator Kgs  
4 Weight of control panel Kgs  
5 Weight of single heaviest piece to be handled during :    
       
  DIMENSIONS    
1 Shipping dimensions    
2 Engine LxBxH Mts  
3 Generator LxBxH Mts  
       

P a g e | 20
N_Arc Consulting IRCON

13. TECHNICAL SPECIFICATION OF CONTROL PANEL

P a g e | 21
N_Arc Consulting IRCON

1.00.00 CONTROL AND INSTRUMENTATION

1.01.00 Start-up, Control, Protection, Metering, Indication

1.01.01 DG sets shall be provided with a DG power Control Panel. Panel shall be
Equipped with adequate control, protection, synchronizing equipment, metering,
Indication /annunciation and other as required auxiliary items. DG starting shall be
AMF type with a provision of manual (push button) starting from DG Control panel
and DG breakers shall be closed manually(from DG control panel) only on
confirmation of steady state voltage and frequency from the DG control Panel and on
fulfillment of other interlocking

1.01.02 It is envisaged that operation, synchronization, control, metering and

monitoring of the DG system will be affected from DG Control panel including for
Operation/control of DG power supply breakers at switch board.

1.01.03 The DG set shall have facility to stop from DG Control Panel under all
operating Conditions.

1.01.04 The DG Control panel shall also be equipped with control and interlock of
Timers ,Protection relays and instruments, selector switches, etc. as required for safe
and Trouble-free operation of the Diesel Generator.

1.01.05 The following items shall be included in the DG Control Panels for each
D.G. Set:

1) Power factor meter

2) AC voltmeter with selector switch

3) AC ammeter with selector switch

4) Frequency meter

5) Kilowatt meter

6) Kilowatt-hour meter

7) SCADA and Programmable Logic Controller, if required.

8) Temperature scanner for winding and bearing

9) Master relays, auxiliary relays as required for smooth and safe

operation of the DG Set.

10) Indicator, annunciation, engine speed and generator voltage raise-

P a g e | 22
N_Arc Consulting IRCON

lower control Switches push buttons, etc.

11) 1 no. signal lamp (set fails to start)

12) 24V lead acid battery with charging equipment

13) Engine start/stop control relays.

14) Push buttons such as start/stop/reset/test etc.

1.01.06 Indicating panel of engine shall be consisting of following:

a) Water temperature gauge

b) Lube oil pressure gauge
c) Lube oil temperature gauge
d) Starting switch with key
e) RPM meter with hour meter
f) Battery charger ammeter

g) Any other item specifically not mentioned here but essential for safe
and Smooth operation and control of DG system.

1.01.07 Readiness to Start

A master relay shall be provided to monitor the pre-requisite conditions to

be met Before the set can be started and an indicating lamp on the DG
control panel shall be provided to indicate when all the requirements are
met. Some of them are

i) Total normal power supply failure i.e. U/V tripping of both the normal
Power Supply I/C feeder.

ii) B/C (if any) between normal and emergency bus is in ‘OFF’ condition.

iii) Pre-requisite conditions for D.C. supply required for engine starting is
satisfied.

1.01.08 Combined DG control panel shall be complete with following provision for
Metering, indication and annunciation of remote end 11 KV Relay control
panel located at Control room;

i) Each DG set starting mode status (AMF/SELECTION)

ii) Operation status (ON/OFF)

P a g e | 23
N_Arc Consulting IRCON

iii) Metering

iv) Trouble Annunciation

v) Emergency off

1.02.00 Tripping

1.02.01 Any one or more of the following defects shall cause the running diesel
generator to be tripped and restart shall be prevented until the fault/faults
are removed and manual resetting is done. Engine and generator
protection shall be made independent. Due to generator problem,
corresponding D.G. incomer breaker in DG control panel shall be tripped
first and engine thereafter with a delay time for safeguard of engine
parameters.

a) Jacket water pressure low.

b) Lube oil pressure.

c) Over-speed.

d) High jacket water temperature.

e) Generator stator temperature very high.

g) Electrical protective relays operated- Electromagnetic/static

 Voltage controlled over current protection (50/51).

 Restricted E/F protection (64)

 Over voltage (59).

 Under voltage (27)

 Reverse Power Earth Fault (32)

 Differential Relay

1.03.00 Indication and Annunciation

For alarm and indication, a hooter and individual indication lamps shall be
provided.
Three nos. push buttons shall be furnished for Accept, Reset and Test.

On occurrence of fault, the hooter shall sound and an indication lamp shall
flash. On pressing accept push button, hooter shall stop but the lamp shall
continue to glow steady. On pressing reset push button, the lamp shall stop

P a g e | 24
N_Arc Consulting IRCON

glowing but if the fault persists, the hooter shall not sound and the lamp
shall glow steadily. Necessary solid- state logic cards, push buttons,
hooters, lamp boxes, etc. shall be furnished as required, to achieve the
above function. However, separate window facia shall be provided for the
following alarm, as a minimum.

D.G. Set Annunciation and Indication

i) Lube oil pressure low

ii) Jacket water temperature high
iii) Fuel oil day tank level low
iv) D.G. Set over speed
v) DG fails to start
vi) Engine common Fault
vii) Emergency Stop
viii) Master trip relay operated
ix) Trip Circuit unhealthy
x) Bearing temperature High
x) Winding temperature High
xi) Differential Trip
xii) Earth Fault Trip
xii Spare

1.04.00 Annunciation System

Solid state alarm annunciators shall be audio-visual, integral back lighted

name plate type with flasher and horn, with in-built pack and sequence
logic. The alarm system shall have one set of “accept”, “reset” and “test”
push button.
Annunciators shall generally be actuated by closing of alarm contact
(normally open Contact). In some case, the reverse configuration may be
required.

The system operating voltage of the annunciation system shall be 24V D.C
Specific Design Requirements

i) The annunciation system shall be designed with adequate safeguard

against Malfunctioning due to random noise and transient pick-ups. An
input filter for draining the high frequency noise, with a built-in adjustable
time delay (Variable from 0-1 second) shall be provided for elimination of
transient pick-Ups and noise.

ii) Annunciation circuitry shall be silicon solid-state plug in module of

state-of-art Technology.

iii) All the components associated with the circuits shall be proven and
guaranteed Quality produced by reputed manufacturers.

P a g e | 25
N_Arc Consulting IRCON

iv) Plug-in-type glass epoxy printed circuit boards with nickel-plated

tracks and gold plated contacts shall be used. The printed circuit boards
shall have suitable Facility for adapting NO and NC type initiating contacts.

v) Printed circuit board shall be channel-wise modular type and shall be

of Polarized construction. The boards shall be properly lacquered.

vi) Annunciation lamps shall be mounted on the top of the panel front.
The lamps shall be serviceable from panel front.

vii) The annunciation system shall incorporate suitable voltage stabilizers

and the Circuit should be immune to step variations in the supply voltage.
The output going to the lamps shall be inherently designed with a current
limiting feature, which restricts the surge current when the lamp comes on.
The lamp drivers Shall also be short-circuit protected.

viii) The annunciators shall be provided with two lamps per channel. The
wattage rating of individual lamps shall be within 2.5 watts and the
enclosure temperature rise with all the lamps glowing shall be guaranteed
within 10C without air-conditioning.

ix) The annunciation windows shall be made of high impact polystyrene

with a display area within 56 mm x 44 mm to 70 mm x 55 mm. The
inscription shall be made on suitable photo film with black letters on white
translucent background. The lettering shall be of 5 mm high, there shall be
maximum 18 characters per line. The inscribed film shall be mounted
behind the translucent Polystyrene windows of white or red colour.

1.05.00 Switches, Lamps, Meter, Control Panel etc.

All electrical components on the panel namely push buttons, switches,
lamps, meters,
Control panels etc. shall meet the system requirements along with the
following
Specification.
1.06.00 Construction of Combined DG Control Panel

a) The panel shall be indoor, air-insulated, dust and vermin proof, metal
enclosed, floor mounting.

b) Minimum thickness of sheet metal used shall be 2mm CRCA and

cable gland plate shall be of min. 3 mm.

c) Cubicle shall have front access doors. All doors and covers shall be
gasket.

P a g e | 26
N_Arc Consulting IRCON

d) All switches, lamps, relays, indicating instruments, annunciations etc.

shall be flush mounted on the panel.

1.06.01 Secondary Wiring

a) The panel shall be fully wired at the factory to ensure proper

functioning of control, protection, transfer and interlocking schemes.

b) Fuse and links shall be provided to permit individual circuit isolation

from bus wires without disturbing other circuits. All spare contacts of
relays, switches and other devices shall be wired up to terminal blocks.

c) Wiring shall be done with flexible 650V grade, PVC insulated

switchboard wires with standard copper conductors of 2.5 mm 2 for control
and current circuits and 1.5 mm2 for voltage circuits.

d) Each wire shall be identified, at both ends, with permanent markers

bearing wire numbers as per contractor’s wiring diagram.

e) Wire terminations shall be made with crimping type connectors with

insulating sleeves. Wire shall not be spliced between terminals.
CT secondary shorting links shall be provided as per requirement.
1.06.02 Terminal Blocks

a) Terminal blocks shall be of suitable voltage grade box clamp type with
making strips. Terminals for C.T. secondary leads shall have provision for
shorting.

b) Not more than two wires shall be connected to any terminal spare
terminals equal in number to 20% active terminals shall be furnished.

c) Terminal blocks shall be located to allow easy access. Wiring shall be

so arranged that individual wires of an external cable can be connected to
consecutive terminals.

1.06.03 Ground Bus

a) A ground bus, of 50 x 6 mm GS flat shall extend full length of the

panel.

b) The ground bus shall be provided with two-bolt with bolts and nuts at
each end to receive 50 x 6mm GS flat.
1.06.04 Nameplates

a) Nameplates of approved design shall be furnished at each cubicle and

at each instrument and device mounted on or inside the cubicle. Cubicle
nameplates shall be provided both at the front and back of the cubicle.

P a g e | 27
N_Arc Consulting IRCON

b) The material shall be lamicoid anodized aluminium or approved equal,

3 mm thick with white letter on black background.

c) The nameplate shall be held with self tapping screws. Nameplate size
shall be minimum 20 x 75 mm for instrument/devices and 40 x 150 mm for
panels.

1.06.05 Space Heaters and Plug Sockets

a) Each panel shall be provided with thermostat controlled 240V space

heater and 6A, 3 Pin plug socket.

b) Cubicle heater, motor heater, plug socket circuits shall have individual
switch fuse units.

1.06.06 Fuses
a) Fuses shall be HRC, preferably link type, with a minimum interrupting
capacity of 12.5 KA short circuit current.

b) Fuses shall be furnished complete with fuse bases and fittings of such
design as to permit easy and safe replacement of fuse element.

c) Visible indication shall be provided on blowing of the fuse.

1.06.07 AC/DC Power Supply

a) For Auxiliary supply Purchaser will provide the LT supply for DG

auxiliary Panel

b) DG control panel shall also have DC Control Power supply for

protection, Indication and annunciation purposes. For which 24V DC
distribution Board with Battery charger shall be provided by vendor.

c) Isolating switch-fuse units shall be provided for power supplies.

d) Door lamp with door switch and one plug socket with switch to be
provided.

1.06.08 Protection

The following protection shall be provided for the generator -

i) Voltage Controlled Over-current Relay (51)

ii) Restricted earth fault protection

iii) Lockout Relay (86)

P a g e | 28
N_Arc Consulting IRCON

iv) Reverse power Relay

v) Differential Relay

Lockout relay shall be fast operating hand-reset type with multi-

contacts for a number of switching operations.
The relay shall be designed for a high degree of mechanical stability
and shall have heavy duty contacts.

vii) Bidder shall also provide all necessary protective devices, under
voltage, over voltage relays as required, timers, auxiliary relays for safe
operation, control and interlock of the Diesel Generating System.

1.06.09 Relays

All the protective relays shall be of draw-out design with built-up testing
facilities or with facilities for testing the relay by inserting test plug and test
plug shall also be furnished. Small auxiliary relays may be in non-draw-out
execution and may be mounted within the cubicle. All the protective relays
indicated above shall be mounted on DG control panel.

All the relays shall conform to latest revision of IS-3231.

1.06.10 Current Transformers

Cast resin type current transformers shall be provided at the generator

terminal box. All secondary connection shall be brought out to DG control
panel where wye or delta connection will be made.
Accuracy class shall be 5P20 for Protection C.T. excepting for REF relay
which should be PS class and Class 1.0 for metering C.T.
VA burden shall be decided by the contractor. Instrument Security Factor
(ISF) for metering CT’s shall be less than or equal to 5 (ISF ≤ 5).
All the metering and protective CTs shall conform to the latest revision of
IS-2705.

1.06.11 Meters

Indicating instruments (96 x 96 mm) shall be switchboard type with 240deg

scale, anti-glare glass and accuracy class of +/- 2% full scale. Each scale
shall have zero adjuster on the front.
Watt - hour meter shall be provided in draw-out cases with built in test
facilities. Alternatively, they may have test block to facilitate testing of meter
without Disturbing CT or VT secondary connections.

P a g e | 29
N_Arc Consulting IRCON

2.0 TECHNCIAL DETAILS OF 11 KV VCB of 630 Amps

DG SET INCOMER: 6 Nos.

630A, Horizontal Draw out type VCB, motorized, suitable for fault level 25KA for 3 sec.
and 11 KV Voltage level with 230V AC spring charging motor, 230v ac motor, 110 volt DC
shunt trip coil, mechanical interlock with required test/Service position selector switch.

 Breaker Control Switch type (TNC)

 Local/Remote Selector Switch
 Digital Voltmeter, Cl: 1
 Digital Ammeter, Cl: 1
 Single Phase Triple core HT Current transformer having following protection with
STR-25KA for 1 Sec. and suitable for 1.1KV system
CORE-1:150/1A,15VA,CL-1
CORE-2: 150/1A,CL-5P10
 Single/Three Phase Single core Draw out type Potential transformer (Line PT)
with primary protection fuse and suitable for 6.6 KV voltage level and Short circult
level of 25KA.for 1 sec. (core-1 for metering)
 Interposing CT
 Phase Indicating Lights R,Y,B,(LED Type)
 VCB Close Indication Red
 VCB Open Indication Green
 VCB Trip Indication Amber
 Spring Charged Indication Blue
 Trip circuit healthy Indication White
 DC Supply Healthy Indication Amber
 6A SPN,10ka, MCB for 230V AC supply
 Control MCB ,10KA C Curve
 Anti-condensation Heater (200W) with thermostat
 Heater Switch
 Secondary Plug & Socket
 CFL for illumination in guarded enclosure-230V
 Aux. Contactor
 Control Terminals

OUTGOING : 2 Nos.
1250 A, Horizontal Draw out type VCB, motorized, suitable for fault level 25KA for 3 sec.
and 11 KV Voltage level with 230V AC spring charging motor, 230v ac motor, 110 volt DC
shunt trip coil, mechanical interlock with required test/Service position selector switch.

 Breaker Control Switch type (TNC)

 Local/Remote Selector Switch
 Digital Voltmeter, Cl: 1
 3 No. Single Phase Triple core HT Current transformer having following
protection with STR-25KA for 1 Sec. and suitable for 1.1KV system
CORE-1:150/1A,15VA,CL-1
CORE-2: 150/1A,CL-5P10

P a g e | 30
N_Arc Consulting IRCON

 3 No. Single/Three Phase Single core Draw out type Potential transformer (Line
PT) with primary protection fuse and suitable for 6.6 KV voltage level and Short
circuit level of 25KA.for 1 sec. (core-1 for metering)
 Interposing CT
 Phase Indicating Lights R,Y,B,(LED Type)
 VCB Close Indication Red
 VCB Open Indication Green
 VCB Trip Indication Amber
 Control MCB ,10KA C Curve

BUS PT PANEL: 1 No.

3 No. Single/Three Phase Single core Draw out type Potential transformer (Line PT) with
primary protection fuse and suitable for 11 KV voltage level and Short circuit level of
25KA.for 1 sec. (core-1 for metering)

NIS CUM NGR PANEL SUITABLE FOR 6X1010 KVA DG SET:

6 No. 400A SP Electrically Latched HT Contactor

6 No. Space Heater with thermostat & Toggle switch
18 No. 150/1A Cast Resin Protection CT,CLPS
18 No. 150/5A Cast Resin Protection CT,CL5P10
1 Set Door Switch,2A
1 set Indicating Light
1 set Aux. Contactor
1 set 10A DP MCB,C Curve ,10KA
1 set 6A SP MCB,10KA
1 set Push Button
1 set A/M Selector Switch,2P 2W-6A

1 no NGR Panel suitable for 1010 KVA 11KV Dg set.

2.1 Electrical Auxiliary power supply

The electrical auxiliary and control power source shall be as follows:
a) AC auxiliary power source
 3 phase 4 wire 50 HZ 415/230V
 1 phase 50 Hz 230 V
 1 Phase 50 Hz 110 V

b) DC control power source 110V shall be provided by purchaser.

3.0 110 V DC Batteries and Battery charger required for control panel. Batteries shall be lead
acid type complete with cable leads lugs etc.

14. SPECIFICATION OF EARTHING

P a g e | 31
N_Arc Consulting IRCON

1.0 EARTHING

1.1.1 GENERAL

All the non –current metal parts of external / internal electrical installation shall be earthed
properly. H.T switchgear, Main L.T. Panel and all other parts made of metal shall be
bonded together and connected by means of specified Earthing conductors to an efficient
Earthing system. Earthing work shall conform to CPWD General Specifications for
Electrical Works (Part I – Internal) – 1994 and Indian Standard specification IS : 3043 –
1987 and relevant Indian Electricity Rules 1956 amended upto date and in the regulations
of the local Electricity Supply Authority.

1.1.2 BODY EARTHING OF EQUIPMENT / OTHER PANELS ETC.

All non-current carrying metal parts of the Electrical equipment shall be connected to
earth system at two points, each of 100% rating. Metallic supports, fencing etc. shall also
be connected to earth system. Body earthing of equipment like H.T Panels, Main L.T
Panels, etc. shall be through a common grid formed in the substation . A main earth ring
shall be formed round the station interconnecting all electrodes. Each equipment shall be
connected with two independent earth conductors. Earthing Grid shall be directly
connected by minimum two independent earth electrodes.

1.1.3 NEUTRAL EARTHING OF EQUIPMENT

Neutral terminals of Diesel Generating set shall be earthed independently. Each neutral
terminal shall be earthed with two independent earth electrodes.

P a g e | 32
N_Arc Consulting IRCON

15. TEST AND COMMISSIONING

1.0 Tests

The Diesel generator sets shall be tested for routine and acceptance tests as per the
relevant IS/IEC standards.

1.1 Commissioning Checks

Commissioning checks and tests shall be included all wiring checks and checking up of
connections, Primary / Secondary injection test for the relays adjustment / setting shall be
done before commissioning in addition to routine Megger test.
In addition to the checks and test recommended by the manufacturer, the Contractor shall
carryout the following commissioning tests to be carried out at site.

i. Load Test

The engine shall be given test run for a period of at least 6 hours. The sets shall be
subjected to the maximum achievable load as decided by Purchaser without exceeding the
specified DG Set rating:

During the load test, half hourly records of the following shall be taken:

a) Ambient temperature.
b) Exhaust temperature if exhaust thermometer is fitted.
c) Cooling water temperature at a convenient point adjacent to the water output from the
engine jacket.
d) Lubricating oil temperature where oil cooler fitted.
e) Lubricating oil pressure.
f) Colour of exhaust gas
g) Speed
h) Voltage, wattage and current output.
i) Oil tank level
The necessary load to carry out the test shall be provided by the purchaser.

ii. Insulation Resistance Test for Alternator

Insulation resistance in mega-ohms between the coils and the frame of the alternator when
tested with a 500V megger shall not be less than IR=2x(rated voltage in KV)+1

iii. Check of Fuel Consumption

A check of the fuel consumption shall be made during the load run test. This test shall be
conducted for the purpose of proper tuning of the engine.

iv. Insulation Resistance of Wiring

Insulation resistance of control panel wiring shall be checked by 500V Megger. The IR shall
not be less than one mega ohm.

P a g e | 33
N_Arc Consulting IRCON

v. Functional Tests

a) Functional tests on control panel.

b) Functional test on starting provision on the engine.
c) Functional tests on all Field devices.
d) Functional tests on AVR and speed governor.

vi. Measurement of Vibration

The vibration shall be measured at load as close to maximum achievable load and shall not
exceed 250microns.

vi. Noise Level check as per relevant standard

vii. Operation checks and lubrication of all moving parts.

viii. Interlocking function check.

ix. Insulation test.

x. Trip tests & protection gear test.

xi. Ratio, polarity and magnetizing characteristics of Current transformers.

xii. Ratio, polarity test of Voltage transformers.

xiii. Testing of protection relays as per manufacturer’s catalogue.

xiv. Testing of metering instruments by secondary injection.

xv. Any other test mentioned elsewhere in this document.

xvi. The tests shall be carried out with the DG set operating at rated speed and at maximum
achievable load. Necessary correction for Test environment condition & background noise
will be applied as per relevant international standard

16 PRE-DESPATCH INSPECTION:-

DGs shall be subject to inspection by a duly authorized representative of the IRCON

International limited. Inspection may be made at any stage of manufacture at the
option of the purchaser and the DGs if found unsatisfactory as to workmanship or
material is liable to rejection. Supplier shall grant free access to the places of
manufacture to IRCON’s representatives at all times when the work is in progress.
Inspection by the IRCON or its authorized representatives shall not relieve the
supplier of his obligation of furnishing DGs in accordance with the specifications.
Material shall be dispatched after specific MDCC (Material Dispatch Clearance
Certificate) is issued by IRCON.

P a g e | 34
N_Arc Consulting IRCON

Following documents shall be sent along with material

a) Test reports
b) MDCC issued by IRCON International limited
c) Invoice in duplicate
d) Packing list
e) Guarantee / Warrantee card
f) Delivery Challan

17. INSPECTION AFTER RECEIPT AT STORES:-

IRCON Inspectors will inspect the material received at IRCON store for acceptance.

18. GUARANTEE:-

The material shall be guaranteed for satisfactory performance for a period of 12 months
from the date of commissioning or 18 months from the date of receipt whichever is earlier.
Any supplies found defective during this period, as a consequence of bad design,
manufacturing or workmanship shall be replaced, free of cost, by you, within a mutually
agreed schedule.

19. QUALITY CONTROL:-

The bidder shall submit within two weeks from LOI, assurance plan indicating the various
stages of inspection, the tests and checks that will be carried out on the material of
construction, components during manufacture and after finishing, bought out items and fully
assembled component and equipment including drives. As part of the plan, a schedule for
stage and final inspection within the parameters of the delivery schedule shall be furnished.
The Purchaser’s / Consultant’s engineer shall have free access to the manufacturer / sub-
supplier’s works to carry out inspections.

20. MINIMUM TESTING FACILITIES:-

Supplier / Manufacturer shall have adequate in house testing facilities for carrying out all
routine tests & acceptance tests as per relevant International / Indian standards.

21. MANUFACTURING ACTIVITES:-

The manufacturer shall have adequate machinery for manufacturing conductors and should
have Quality Assurance Manual, which shall be approved by IRCON international Limited.

22. SCHEDULE OF DEVIATIONS:-

The Bidders shall set out all deviations from this specification, clause by clause in this
schedule. Unless specifically mentioned in this schedule, the tender shall be deemed to
confirm the purchaser’s specifications. (Format is attached).

P a g e | 35
N_Arc Consulting IRCON

Appendix - A
Project: Rail Coach Factory, Rae Bareli.

Bid Document No
Tender Notification No.

TECHNICAL DEVIATIONS

The following are the Technical Deviations and Variations from and Exceptions to the specifications
and documents for the subject package. These deviations and variations are exhaustive. Except
these deviations, the entire work shall be performed as per your specifications and documents.
———————————————————————————————————————----
Vol./Clause Ref./Page No. As specified Technical deviation
in the specification and variations to the
specification
———————————————————————————————————————----

———————————————————————————————————————----

Date: (Signature)......................................
Place: (Printed Name)................................
(Designation)...................................
(Common Seal)................................
Note :

i. Continuation sheets of like size and format may be used as per Bidder's requirements and
annexed to this schedule.
ii. The deviations and variations, if any, shall be brought out separately for each of the
equipment
iii. In the event of no deviation, the bidder shall mark "NO DEVIATIONS" in the description
column and duly sign.
iv. Deviations which are not specifically brought out in the above format are not valid.

P a g e | 36
N_Arc Consulting IRCON

LIST OF APPROVED MAKES OF MATERIAL

S. No. Details of equipment/ material Makes

1. Diesel Engine Jakson / Cummins Engine / Caterpillar Engine / L& T

Engine/ Perkins Engine /powerica.

2. Alternators Leroy-Somer / Stamford / Kirloskar /Toyodenki

3 Anti Vibration Mountings Gerb/ Resistoflex/Diesel Manufacturer recommended

4 Battery Amco/Standard/ Prestolite/Exide/cummins pulse lite

5 Battery Charger (Solid state with AE / Waves Electronics/ Chhabi Electric/jakson

Safeties)

6 Motors CGL/ABB/NGEF/ Siemens/ Kirloskar

7 Pipes Tata / Jindal / Surya

8 Valves C & R/ Key Stone/ Audco/Sant/zoloto/leader

9 Flexible Coupling Resistoflex/Kanwal

10 Cables Universal/Finolex/Unistar/golster/KEI

11 Termination (Lugs) Jainson/ Commet/Dowell

12 Double Grip Glands Gripwel/ Commet/ HMI

13 Residential Silencer Nelson/ Cummins/ as per Supplier (supplier shall

submit noise level calculation & shop drawing for
consultants review).

14 Pump Sets Maxflow/Beacon/ Kirloskar/Mather Platt/ Crompton

15 MS Pipes for Exhaust System Tata/ Jindal / Surya

16 MS Pipes/ GI pipes for fuel system Tata/ Jindal / Surya

17 Pressure/Temperature Gauges H Guru/ Feibig

18 Insulation Llyod/ UP Twiga/Kimco

19 MV Switchboards/ Synchronizing Panel Jakson/Sudhir/Powerica

20 Current Transformers Precise/C&S/ AE/Gilbard

P a g e | 37
N_Arc Consulting IRCON

21 Selector Switches Control & Switchgear/ Siemens/ Kaycee/L&T

22 Vibrator Eliminator Kanwal/Resistoflex

23 Cable Trays Needo/ Pilco/ Riico Steel/Slotco

24 Semi Rotary type hand fuel filling pump Rotodel/ Kitty

25 11KV DG Power Panel Areva/ Crompton/ABB/Schneider

27 Dg synchronizing Panel Jakson/Sudhir/Powerica
28 HT termination Kit Raychem/3M

P a g e | 38